Abstract
The single-point diamond turning is widely used as an ultra-precision fabricating method of freeform optics. However, the remounting error of the workpiece and the misalignment error of the cutting tool will reduce the manufacturing accuracy. As a result, an alignment method is needed to specify the actual position of the remounted workpiece. Monoscopic deflectometry is a high-precision, low-cost and high-dynamic range measurement method for specular surfaces. The structural simplicity and flexibility make it suitable for the in-situ measurement and monitoring. A method of workpiece positioning is proposed based on monoscopic deflectometry. A mathematical model is constructed assisted with reverse ray tracing and workpiece rotation around the main spindle. The geometrical pose and location of the workpiece are solved by minimizing the re-projection error of ray tracing. This method effectively decouples different degrees of freedom of the workpiece, and the remounting error can be suppressed accordingly. Experimental result shows that the positioning accuracy is comparable with that of a coordinate measuring machine.
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